200tdi defender

Harry121 · Dec 20, 2021

Hi. Me and a few mates have just put a 200tdi in my defender. On idle it sounds fine as soon as you apply throttle almost full it pops and crackles. People have been saying lift pump so we changed that. Done Injectors. Timing. Any help would be much appreciated. We think it’s a fuel problem maybe starving itself of fuel. But I would imagine this is the place to ask a lot more experienced people on here.

Flossie · Dec 20, 2021

Check the banjo bolts are fitted in their correct ports on the FIP. You'll have to remove them to check. The flow banjo bolt has a much larger port in it than the return.

payydg · Dec 21, 2021

Harry121 said:
Hi. Me and a few mates have just put a 200tdi in my defender. On idle it sounds fine as soon as you apply throttle almost full it pops and crackles. People have been saying lift pump so we changed that. Done Injectors. Timing. Any help would be much appreciated. We think it’s a fuel problem maybe starving itself of fuel. But I would imagine this is the place to ask a lot more experienced people on here.

Yeh that’s odd. I would tend to agree and say a fuel issue. If you’ve done the injectors and pump just got to work backwards from them.

tottot · Dec 21, 2021

Are you revving it up " as soon as you apply throttle almost full " at a stand still ? If so it wont like it, without a load on the engine.

landowner · Dec 21, 2021

Mine popped through the exhaust, it was a slightly bent conrod, smoked a bit when cold as well, if all else fails try a compression test

Harry121 · Dec 22, 2021

here is a clip of my truck let me know if it doesn’t work. Thank you

potus · Dec 22, 2021

I'm no 200tdi expert but its fairly smokey, doesn't look like its starving of fuel.
Wondered if a lack of exhaust back pressure would cause any problems?
The eggsperts shall be along shortly..

Harry121 · Dec 22, 2021

potus said:
I'm no 200tdi expert but its fairly smokey, doesn't look like its starving of fuel.
Wondered if a lack of exhaust back pressure would cause any problems?
The eggsperts shall be along shortly..

any help is appreciated mate expert or no expert I’m quite enjoying learning from all different answers. Thanks mate

flat · Dec 22, 2021

potus said:
I'm no 200tdi expert but its fairly smokey, doesn't look like its starving of fuel.
Wondered if a lack of exhaust back pressure would cause any problems?
The eggsperts shall be along shortly..

turbos give the required back pressure. My tdi ran just fine with no exhaust when I rebuilt it

landowner · Dec 22, 2021

Have you checked lift pump and fuel filter, good pressure and no leaks ?

Harry121 · Dec 22, 2021

tottot said:
Are you revving it up " as soon as you apply throttle almost full " at a stand still ? If so it wont like it, without a load on the engine.

but surly if it’s revving up it still shouldn’t sound like that with or without load ?

Harry121 · Dec 22, 2021

landowner said:
Mine popped through the exhaust, it was a slightly bent conrod, smoked a bit when cold as well, if all else fails try a compression test

Is that an easy fix

tottot · Dec 23, 2021

Harry121 said:
but surly if it’s revving up it still shouldn’t sound like that with or without load ?

If the engine has just been started it is quite common for an old engine to miss some until a lazy pot warms up. This can be because a cylinder is down on compression or its glow plug is not good. What a load does is warm it up quicker.
Has the engine been stood for some time before being fitted ? Did you see it run before it went in your truck ?

landowner · Dec 23, 2021

Harry121 said:
Is that an easy fix

Not easy fix, but mine still revved ok and didnt smoke once warm so l suspect yours is fuel or pump timing

Harry121 · Dec 23, 2021

tottot said:
If the engine has just been started it is quite common for an old engine to miss some until a lazy pot warms up. This can be because a cylinder is down on compression or its glow plug is not good. What a load does is warm it up quicker.
Has the engine been stood for some time before being fitted ? Did you see it run before it went in your truck ?

so we have had it sat for a bit but we have also now had it started for a while like it’s been started a few times now and still sounds the same. And yes we seen a video of it running etc and it was fine.

tottot · Dec 23, 2021

Having watched the video several times now I still recon one or two pots is not playing right. Possible causes. down on compression, stuck rings, no glow, injector faulty [ even if new ], as Flossie says banjo's the right way around, timing out, the 200 will run even a tooth out.

Harry121 · Dec 23, 2021

tottot said:
Having watched the video several times now I still recon one or two pots is not playing right. Possible causes. down on compression, stuck rings, no glow, injector faulty [ even if new ], as Flossie says banjo's the right way around, timing out, the 200 will run even a tooth out.

Okay thank you. What would you say to start with or is it something you can fix for example. What would you check next. Sorry for the questions thank you

tottot · Dec 23, 2021

No problem, easy stuff first. Banjo's and glow plug, get it up to higher temp by driving if you can stuck rings can free. Timing check. But perhaps do this first unless 100% you got it right.

flat · Dec 24, 2021

Check valve clearance and all that basic stuff first aswell

lynall · Dec 24, 2021

Start at tank sender, remove it and check then go forwards and remove/check every part, never assume its okay even if it was ok last time you looked or if its new.
If you have seen a video of it running nice, then your installation must have an issue
New fuel pipes? New fuel filter, or is the old one still in place, what about the sedimenter?
What engine was in the car before?

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